CN1463061A - Method of mfg. spark plug - Google Patents
Method of mfg. spark plug Download PDFInfo
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- CN1463061A CN1463061A CN03137873A CN03137873A CN1463061A CN 1463061 A CN1463061 A CN 1463061A CN 03137873 A CN03137873 A CN 03137873A CN 03137873 A CN03137873 A CN 03137873A CN 1463061 A CN1463061 A CN 1463061A
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- middleware
- noble metal
- metal thin
- thin slice
- electrode body
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01T—SPARK GAPS; OVERVOLTAGE ARRESTERS USING SPARK GAPS; SPARKING PLUGS; CORONA DEVICES; GENERATING IONS TO BE INTRODUCED INTO NON-ENCLOSED GASES
- H01T21/00—Apparatus or processes specially adapted for the manufacture or maintenance of spark gaps or sparking plugs
- H01T21/02—Apparatus or processes specially adapted for the manufacture or maintenance of spark gaps or sparking plugs of sparking plugs
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/51—Plural diverse manufacturing apparatus including means for metal shaping or assembling
- Y10T29/5193—Electrical connector or terminal
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/51—Plural diverse manufacturing apparatus including means for metal shaping or assembling
- Y10T29/5195—Tire valve or spark plug
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- Spark Plugs (AREA)
Abstract
Provided is a method of making a spark plug having a noble metal chip joined to an electrode main body of a ground electrode by interposing therebetween an intermediate member. The method comprises the steps of prior to joining the noble metal chip to the electrode main body, joining the intermediate member and the noble metal chip together, placing a noble metal chip and intermediate member assembly on the electrode main body in a way as to allow the intermediate member to contact the electrode main body, and welding the electrode main body and the intermediate member together while restricting relative movement of the electrode main body and the intermediate member without applying an urging force to a joint between the intermediate member and the noble metal chip.
Description
Background of invention
The present invention relates to a kind of method of making spark plug.
The multiple spark plug of following kind has been proposed so far, wherein being welded on the end of electrode, so that improve the resistance that spark is consumed by comprising the metal noble metal end as main component such as Pt, Ir.Because its polarity is changed to negative central electrode side and stands the strong adhesion of spark and be easy to consume in that sparkover is standing often, so the noble metal thin slice can produce arc effect in being used in central electrode the time.Yet along with the increase of such spark plug for the application of height output engine or poor combustion engine, the noble metal thin slice also increases in the ground electrode side and adopts, so that the requirement of electrode side with the high resistance that consumes for spark contentedly.So far, be the alloy manufacturing at the noble metal thin slice of ground electrode side by Pt, and be welded on the main body of the ground electrode of making by Ni alloy etc.
The present invention's general introduction
When the joint of noble metal thin slice and electrode body, at first the noble metal thin slice is placed on the electrode body.Sheet metal and electrode body are clamped between the exciting electrode then, and when compressing by heating to the exciting electrode supplying electric current.Yet, by this method, when welding, excessive pressure is applied on the composition surface of noble metal thin slice and electrode body, thereby the defective such as crackle is easy to be retained in after welding in the composition surface between noble metal thin slice and the electrode body, thereby might cause noble metal thin slice and electrode body problem separated from one another easily when standing to circulate heating and cooling.
Particularly, in order more effectively to suppress the spark consumption of ground electrode side, the material of checking the noble metal thin slice recently is that alloy changes to and has more that the Ir of high-fire resistance is an alloy from the main always Pt that uses so far.Yet, because by Ir is that the noble metal thin slice that alloy is made has high-melting-point, so when fashionable by resistance welded and since not enough fusing etc. between noble metal thin slice and electrode body in being easy to cause defective joint interface, thereby cause above-mentioned crackle or separate incident problem.And, except that not enough fusing, the Ir that constitutes the noble metal thin slice be alloy with the Ni that constitutes the ground electrode main body be linear expansion coefficient between the alloy be crackle and the reason of separating than big difference.
In order to alleviate the defective that causes by the linear expansion coefficient difference, proposed inserting a middleware between noble metal thin slice and the electrode body with the linear expansion coefficient between noble metal thin slice and electrode body.Yet, weld noble metal thin slice and electrode body if middleware is inserted between it and by apply elevated pressures to it by electric resistance welding, then when middleware is cut into electrode body with noble metal thin slice major part, be easy to cause crackle in the office, junction surface of middleware and noble metal thin slice or separate, thereby can not overcome the above problems satisfactorily.
Thereby one object of the present invention is, a kind of method of making spark plug is provided, and this spark plug causes such as crackle or the defective separating at the composition surface place of noble metal thin slice and ground electrode main body on the electrode body that the noble metal thin slice is welded to ground electrode the time hardly.
In order to realize above purpose, the invention provides a kind of method of making spark plug, this spark plug comprises: a ground electrode has an electrode body; With a noble metal thin slice, join on the electrode body by between it, inserting a middleware, the noble metal thin slice is arranged to limit facing to a central electrode and between it spark-discharge gap, the method comprising the steps of: before joining to the noble metal thin slice on the electrode body, middleware and noble metal thin slice are bonded together, and form a noble metal thin slice and middleware component thus; Noble metal thin slice and middleware component are placed on the electrode body in such a way, thereby allow middleware contact electrode main body; And the electrode body of noble metal thin slice and middleware component and middleware are welded together, limit the relative motion of the electrode body and the middleware of noble metal thin slice and middleware component simultaneously, and need not be applied to thrust on the composition surface between middleware and the noble metal thin slice by using the another one part.
In the method for the invention, the noble metal thin slice is once joined on the middleware, and realize noble metal thin slice and the middleware of middleware component and contacting of electrode body.Electrode body and middleware weld together when limiting its relative motion, and need not be applied to the thrust that is used for promoting to be adjacent to each other on electrode body and the middleware by using the another one part.Promptly; owing to being unlike in, welding middleware and noble metal thin slice stand so excessive power in the prior art electric resistance welding like that, so crackle or detachment defects are located to cause in the composition surface that might protect spark plug to avoid between middleware and noble metal thin slice reliably that becomes.
In the production of noble metal thin slice and middleware component, preferably realize the joint of middleware and noble metal thin slice by LASER BEAM WELDING.LASER BEAM WELDING can more easily be concentrated heat, and makes the depth of weld bigger, thereby makes and might prevent reliably that place, composition surface between middleware and noble metal thin slice from causing crackle or separate.
And, can carry out the welding of middleware and electrode body by LASER BEAM WELDING or by electric resistance welding.Specifically, under the situation that adopts electric resistance welding, the place, composition surface between middleware and noble metal thin slice does not have any possibility of excessive pressure, and needn't worry that crackle or separation appear in the place, composition surface between them.
In LASER BEAM WELDING or electric resistance welding, wish to apply a thrust, so that they are kept putting in place contacting with being fitted to each other greater than a predetermined value to middleware and electrode body.For thrust being applied on middleware and the electrode body and can not cause that excessive forces acts on the composition surface between middleware and the noble metal thin slice, carries out following steps.That is, in placing step, consider that the projected area of the composition surface of middleware and electrode body becomes a minimum projection plane thereon.On projection plane in the rectangular projection of middleware and electrode body, is a zone definitions that overlaps each other in view field of its place middleware and electrode body one first overlapping region, and is a zone definitions that overlaps each other in view field of its place's middleware and noble metal thin slice one second overlapping region.In first overlapping region, form a Non-overlapping Domain that does not belong to second overlapping region.Then, being used for promoting the be fitted to each other thrust that contacts of middleware and electrode body to one is applied on the part with corresponding middleware of the Non-overlapping Domain of first overlapping region and electrode body, and under this condition, middleware and electrode body are welded together.That is,, thrust is not applied on the composition surface of middleware and noble metal thin slice by applied thrust on Non-overlapping Domain only.
And, in placing step, electrode body can have one and have the through hole or the blind hole of an open end facing to place, the side of central electrode, and noble metal thin slice and middleware component can be inserted in through hole or the blind hole in such a way through the open end, thereby allow noble metal thin slice and middleware component outstanding from the open end.By noble metal thin slice and middleware component are inserted in the through hole or blind hole of electrode body, can limit noble metal thin slice and middleware component and electrode body in the relative motion that strides across on the direction of its direction of insertion, thereby make might be reliably and realize the welding of electrode body and middleware effectively.
In this example,, can produce a motive force by on direction of insertion, pushing middleware by means of a thrust piece.By by means of using thrust piece initiatively middleware to be pushed against on the electrode body, though through hole or blind hole on diameter greater than middleware, also can limit the relative motion of electrode body and middleware reliably.In this example, by thrust piece as welding electrode with by by means of welding at the electric resistance welding that carries out with the office, junction surface of corresponding middleware of Non-overlapping Domain and electrode body, can be easily and realize welding step reliably.
The noble metal thin slice can be made by the Ir alloy.As mentioned above, Ir is that the noble metal thin slice of alloy has high-melting-point, thereby when carrying out the joint of noble metal thin slice by conventional electric resistance welding, is easy to cause crackle or separation at junction point.Yet by means of the present invention, excessive pressure can not act on the composition surface of noble metal thin slice and middleware, thereby can cause crackle or detachment defects hardly, although the Ir alloy is used for forming the material of noble metal thin slice.In this example, when engaging the noble metal thin slice made by the Ir alloy and middleware by the LASER BEAM WELDING that can realize big depth of fusion and highly reliable joint, can obtain more effective result.
And, by forming middleware by metal with the linear expansion coefficient between the metal that forms noble metal thin slice and electrode body, compare with situation about wherein the noble metal thin slice directly being joined on the electrode body, can reduce the adverse effect that the difference by linear expansion coefficient causes, thereby make and to prevent more effectively that place, composition surface between noble metal thin slice and middleware from causing crackle or separate.
Brief description of the drawings
Fig. 1 is the longitudinal sectional view of the spark plug made by method according to an embodiment of the invention;
Fig. 2 is the amplification view of the pith of Fig. 1 spark plug;
Fig. 3 A to 3C is the view that is used for showing step in the method for the invention;
Fig. 4 A and 4B are the views that is used for showing from the step in the method for the invention of Fig. 3 A to 3C continuation;
Fig. 5 is the improved view that is used for showing the method for Fig. 1 to 4A and 4B;
Fig. 6 is the another kind of improved view that is used for showing the method for Fig. 1 to 4A and 4B;
Fig. 7 is the view that is used for showing the further improvements in methods of Fig. 1 to 4A and 4B;
Fig. 8 is the view that is used for showing the further improvements in methods of Fig. 1 to 4A and 4B;
Fig. 9 is the view that is used for showing the further improvements in methods of Fig. 1 to 4A and 4B;
Figure 10 A to 10D is used for showing the view of method in accordance with another embodiment of the present invention;
Figure 11 is the improved view that is used for showing the method for 10A to 10D;
Figure 12 A to 12C is the improved view that is used for showing the method for Fig. 1 to 4A and 4B;
Figure 13 A and 13B are the views that is used for showing the method for other embodiment according to the present invention;
Figure 14 is the view that is used for showing the method for other embodiment according to the present invention;
Figure 15 A and 15B are the views that is used for showing the method for other embodiment according to the present invention; And
Figure 16 A and 16B are the views that is used for showing the method for other embodiment according to the present invention.
The detailed description of most preferred embodiment
At first with reference to Fig. 1, a spark plug is generally indicated by 100, and comprises: a cylindrical metal shell 1; An insulator 2 is assemblied in the metal-back 1, and has the end of giving prominence to from metal-back 1; A central electrode 3 is arranged in the insulator 2, and has the guiding end of giving prominence to from insulator 2; And a ground electrode 4, welding at one end or otherwise be fixed on the metal-back 1, and bend to and make another end face facing to the guiding end (being end surfaces) of central electrode 3.Ground electrode 4 comprises that an electrode body 4m and one join noble metal thin slice 32 on the electrode body 4m to by insert a middleware 33 between it.Noble metal thin slice 32 is facing to central electrode 3, thereby forms a spark-discharge gap g between it.Central electrode 3 has a main body 3m and a noble metal thin slice 31 that is welded on main body 3m one end.Noble metal thin slice 32,31 by comprise Ir as main component (greater than weight 50%) precious metal alloys and make from 3 to 50% at least a auxiliary precious metal element that accounts for total weight of the group selection formed by Pt, Rh, Ru and Re.
Insulator 2 is formed by the ceramic sintered bodies such as aluminium oxide or aluminium nitride, and has a wherein hole of assembly center electrode 3.And metal-back 1 is tubular, and is made by the metal such as mild steel.Metal-back 1 constitutes the outer cover of spark plug 100, and has on its outer surface and be used for spark plug 100 is attached to threaded portion on the engine block (not shown).
And a middleware 33 that is provided to ground electrode 4 is made by the metal with the linear expansion coefficient between the metal that constitutes noble metal thin slice 32 and electrode body 4m respectively (electrode matrix material).Specifically, can adopt Ir-Ni alloy or Ir-Ni-Rh alloy.For example, if noble metal thin slice 32 is by comprising Ir weight 97% or littler and make from the metal of 3% or bigger at least a element of the group selection be made up of Pt, Rh, Ru and Re, then middleware 33 can be made by 20% or bigger metal of 30% or bigger and Rh and the Ni total weight that comprise Ir and Rh total weight.Simultaneously, wish that more middleware 33 comprises Ni as indispensable composition,, thereby can make the difference of the coefficient of expansion between it and fusing point less because electrode body 4m makes as the electrode matrix metal of main component by comprising Ni.
As shown in Figure 2, the leading end part 3a of central electrode 3 is tapered so that reduce cross section to leading end, and has a flat leading end face.On flat leading end face, place noble metal thin slice 31.Form a welding portion B by means of LASER BEAM WELDING, electron beam welding, electric resistance welding etc. by edge, noble metal thin slice 31 is joined on the leading end part 3a of central electrode 3 along the composition surface.
The electrode body 4m of ground electrode 4 is formed with the through hole 4v that has the open end at the side surface place.In through hole 4v, insert middleware 33.Middleware 33 is distolateral being tapered so that reduce cross-sectional area of guiding, and have one its go up the leading end face of placement noble metal thin slice 32.By annular, circumference LASER BEAM WELDING part B noble metal thin slice 32 is joined on the middleware 33.Outstanding so that be exposed to outside side from its noble metal thin slice 32, promptly arrange the place, side of one second open end SO of through hole 4v therein, the inner circumferential surface of through hole 4v has an annular that makes the second open end SO reduce cross-sectional area, radially inner ledge 4s.Middleware 33 is in conical surface 33t place and the conical surface 4t engagement that is formed on ledge 4s place, and prevent from thus to go up landing or separation, and by joining on the ground electrode main body 4m at the welding portion R that place, the composition surface between poppet surface 33t and the poppet surface 4t forms by means of electric resistance welding from ground electrode main body 4m.
With reference to Fig. 3 A-3B and 4A-4B, will method that make above-mentioned spark plug 100 be described.This method consists essentially of following three steps.
(1) before joining on the electrode body 4m, middleware 33 and noble metal thin slice 32 are bonded together to form a noble metal thin slice and middleware component 34 (engagement step).
(2) noble metal thin slice and middleware component 34 are placed on the electrode body 34 in such a way, thereby allow middleware 33 contact electrode main body 4m (placement step).
(3) electrode body 4m and noble metal thin slice and middleware component 34 are welded together, condition is to prevent that them from relative to each other moving, and need not be applied to thrust on the composition surface between middleware 33 and the noble metal thin slice 32 (welding step) by using another part.
At first, as shown in the step 1 of Fig. 3 A, the blank or the workpiece 133 that are used for middleware 33 are formed with a flat leading end face 133a and a conical surface 33t by cutting head, and the noble metal thin slice 32 of disc format are placed on the leading end face 133a of the workpiece 133 that is used for middleware 33.Then, as shown in the step 2 in Fig. 3 B, a laser beam LB is applied to the exterior periphery periphery of workpiece 133 and noble metal thin slice 32 its composition surfaces of upper edge, is formed on the annular solder part B that extends between noble metal thin slice 32 and the cylindrical work 133 thus.Simultaneously,, then can cut unnecessary length part 133W if workpiece 133 has a unnecessary length part 133W in the part place in its back-end, and as shown in the step 3 of Fig. 3 C (certain, if, then can save step 3) without any unnecessary length part.By this way, workpiece 133 is formed the middleware 33 that has conical surface 33t, and engage to constitute noble metal thin slice and middleware component 34 with noble metal thin slice 32.
Then, as shown in the step 4 of Fig. 4 A, electrode body 4m is formed with at the through hole 4v that has an open end facing to the place, side of central electrode 3.Then, in above-mentioned placement step, noble metal thin slice and middleware component 34 are inserted among the through hole 4v through the first open end PO, so that allow noble metal thin slice 32 outstanding from the second open end SO.Be formed on conical surface 4t in the inner surface of through hole 4v as electrode side mating surface, and be formed on conical surface 33t in the middleware 33 of intermediate module 34 as middleware side mating surface.By the engagement of conical surface 4t and conical surface 33t, prevent that middleware 33 from coming off on the direction of insertion that it is inserted among the through hole 4v.
Like this, middleware 33 and electrode body 4m are formed with a composition surface that is placed on another, promptly the conical surface 33t of the conical surface 4t of through hole 4v and middleware 33 stacked or one be placed on another.Hereinafter, composition surface is promptly indicated by 33t by the label indication that is used for middleware 33 sides.
Here, one of consideration allows the projection plane P that the projected area of the composition surface 33t of middleware 33 and electrode body 4m becomes minimum.In this embodiment, projection plane P is a plane with the axes O of right angle intersection middleware 33.On the projection plane P in the rectangular projection of middleware 33 and electrode body 4m, the zone definitions that view field at its place's middleware 33 and electrode body 4m is overlapped each other is one first overlapping region 33t ', and the zone definitions that the view field at its place's middleware 33 and noble metal thin slice 32 is overlapped each other is one second overlapping region J '.In this embodiment, the first overlapping region 33t ' is corresponding with the view field of conical surface (composition surface) 33t, and the second overlapping region J ' corresponding with the view field of the joint interface J of middleware 33 and noble metal thin slice 32 (in Fig. 4 A, the bonding part of middleware 33 and noble metal thin slice 32 is illustrated under the state of putting into after their welding).Thereby the first overlapping region 33t ' forms a Non-overlapping Domain that does not belong to the second overlapping region J ' as a whole.
The step 5 of Fig. 4 B shows welding step.At first, being used for promoting middleware 33 and motive force that electrode body 4m contacts with being fitted to each other is applied on the part with the corresponding middleware 33 of the Non-overlapping Domain of first overlapping region, promptly be applied to here on conical surface (composition surface) 33t, and under this condition, middleware 33 and electrode body 4m are welded together.In this embodiment, all composition surface 4t, 33t of electrode body 4m and middleware 33 are corresponding with Non-overlapping Domain, thereby thrust only is applied on the part ( composition surface 4t, 33t) with corresponding middleware 33 of Non-overlapping Domain and electrode body 4m inevitably.
And, when on direction of insertion, promoting or during pushing middleware 33, locating to produce reliably one at conical surface 33t (Non-overlapping Domain) and be used for promoting the motive force that middleware 33 is adjacent to the conical surface 4t of electrode body 4m by means of a thrust piece 50.In step 5, thrust piece 50 is as a welding electrode, and is being that conical surface 33t place corresponding to the part of Non-overlapping Domain carries out electric resistance welding.
Among the embodiment that in Fig. 4 A and 4B, represents, as shown in the step 4, be inserted into noble metal thin slice and middleware component 34 among the through hole 4v and arrange within it through the first open end PO, thereby noble metal thin slice 32 is outstanding from the second open end SO.As shown in step 5, realize a strutting piece 51 with around the contacting of the part of the electrode body 4m of the second open end S0, so that do not interfere with noble metal thin slice 32.Specifically, by at the electrode that has a negative area 51a with noble metal thin slice 32 corresponding positions as strutting piece 51 and allow noble metal thin slice 32 to be received in the negative area 51a, avoid above-mentioned interference.Under this condition, the middleware 33 that is positioned in the first open end PO compresses strutting piece 51 by means of the electrode that constitutes thrust piece 50.By between thrust piece 50 and strutting piece 51, supplying with a welding current 52 under this condition, locate to form electric resistance welding part R at conical surface 33t (Non-overlapping Domain).
Simultaneously, in Fig. 4 A and 4B, electrode body 4m is arranged to allow the first open end PO to be positioned at higher place.Thereby, when being inserted into noble metal thin slice and middleware component 34 among the through hole 4v, realize that by means of the gravity that acts on the middleware 33 the conical surface 33t (Non-overlapping Domain) of middleware 33 and the conical surface 4t of through hole 4v contact with each other, thereby make middleware 33 compress conical surface 4t by gravity.This motive force is always not enough for electric resistance welding.Yet, because middleware 33 is inserted among the through hole 4v, thus restriction middleware 33 and electrode body 4m with the crossing direction of direction of insertion on motion.That is, can limit both composition surface (conical surfaces: relative motion Non-overlapping Domain).Thereby, by adopting laser welding, can engage middleware 33 and electrode body 4m and without any problem.Fig. 5 represents that wherein LASER BEAM WELDING part Q forms an example that extends to middleware 33 from the leading end face side of electrode body 4m.And Fig. 6 represents that one of them annular laser beams welding portion U-shaped becomes an example that extends between electrode body 4m and middleware 33.And, as shown in Figure 7, can provide LASER BEAM WELDING part Q and electric resistance welding part R.
Simultaneously, feasible is, the middleware side engagement surfaces is not conical surface 33t, but has shown in Fig. 8 the ladder circumferential surface of a plurality of flat ledge surface 33s1,33s2 shown in a flat ledge surface 33s or Fig. 9.Middleware 33 since ledge surface 33s (Fig. 8) or ledge surface 33s1,33s2 (Fig. 9) provide thus cross-sectional area stepping ground reduces.And the inner circumferential surface classification of through hole 4v is so that have and the ledge surface 4j (Fig. 8) of ledge surface 33s engagement or ledge surface 4j1, the 4j2 (Fig. 9) that meshes with ledge surface 33s1,33s2.Locate or locate at ledge surface 33s (Fig. 8), can form an electric resistance welding part or all part R respectively at ledge surface 33s1,33s2 (Fig. 9).
Hereinafter, with reference to Figure 10 A to 10D a kind of method of making spark plug according to a further embodiment of the invention will be described.
In Figure 10 A, the guide end surfaces of middleware 33 (first end surfaces) 33a is a composition surface of placing noble metal thin slice 32 on it.Middleware 33 is formed with the negative area or the blind hole 33h (step 1) that have an open end at the second end face 33e place that it is not engaged noble metal thin slice 32.By means of blind hole 33h, middleware 33 is formed with a thin-walled portion 33w adjacent with guide end surfaces 33a.Bottom by LASER BEAM WELDING being applied to blind hole 33h (that is, laser beam irradiation to the bottom of blind hole 33h) can weld together middleware 33 and noble metal thin slice 32.Such welding has such advantage: even can not obtain under the situation of enough depths of weld by the side surface that LASER BEAM WELDING is applied to middleware 33, and the also bond strength that can be improved.
In this embodiment, a LASER BEAM WELDING part B at first forms along the outer peripheral edges extensions (step 2) of the composition surface of noble metal thin slice 32 and middleware 33.And, laser beam LB from the distolateral irradiation of the opening of blind hole 33h to its bottom, form to see through another LASER BEAM WELDING part BW (step 3) that thin-walled portion 33w enters noble metal thin slice 32 thus.In this connection, can be with reverse order execution in step 2 and step 3.
Then, as shown in the step 4 of Figure 10 D, place step and welding step basically with Fig. 4 A and 4B in represent identical, thereby difference between them is only described.Middleware 33 forms conical butt, and has an almost tapered as a whole external peripheral surface 33t.The through hole 4v of electrode body 4m has a corresponding tapered inner circumferential surface 4t of the taper external peripheral surface with middleware 33.Be bonded together by an electric resistance welding part R with external peripheral surface 4t and 33t in the taper.Simultaneously, as shown in Figure 11, the blind hole 33h that is used for forming LASER BEAM WELDING part BW can be filled with a kind of metal charge 33f.This filling can realize by for example built-up welding.
And the shape of cross section of the middleware that obtains along the plane vertical with the direction of engagement O of middleware 33 is not limited to circle, but can be the different shape such as rectangle.For example, as shown in Figure 12 A to 12C, if when the cross-sectional area of wishing to make noble metal thin slice 32 is big, adopt by the chain-dotted line indication and have the middleware 33 of circular cross section ', a kind of like this situation then might take place, the width of electrode body 4m d ' deficiency or too little wherein, and become and be difficult to middleware 33 ' successfully be embedded among the electrode body 4m.In this example, be to adopt the middleware that does not have circular cross section but have the flattened cross-sectional of all rectangular cross sections as shown in Figure 12B and so on effectively.That is, suppose that middleware 33 has the cross section on a minor face d and a long limit 1, in such a way middleware 33 is embedded among the electrode body 4m really, thereby the direction of elongating minor face d overlaps with width d ' direction of electrode body 4m.Simultaneously, as shown in Figure 12 C, can produce middleware 33 with such flat pattern by depressing frustum of a cone workpiece 33c from the radially opposite side of central shaft M or reducing thickness by the processing such as grinding.
Figure 13 A and 13B represent an additional embodiments.As shown in Figure 13 A, middleware 33 has one first end face 33x and one second end face 33y relative on direction of engagement O.Noble metal thin slice 32 joins on the first end face 33x.Middleware 33 is placed on the electrode body 4m in such a way, contacts with electrode body 4m so that realize the second end face 33y.It is littler than the first end face 33x that the composition surface J-shaped of noble metal thin slice 32 becomes area.As shown in Figure 13 B, push middlewares 33 against electrode body 4m by means of thrust piece 50 at a surf zone 33p place that does not provide noble metal thin slice 32.In this method, by realizing contacting of thrust piece 50 and the surface portion 33p that noble metal thin slice 32 is not housed, can be against electrode body 4m pushing middleware 33, and need not push noble metal thin slice 32, thereby help to prevent that the place, composition surface between noble metal thin slice 32 and middleware 33 from causing crackle and preventing that they are separated from one another.Consider that according to above-mentioned projection plane P the integral body of the second end face 33y of middleware 33 is corresponding with first overlapping region, and be included in fully in the second end face 33y with the composition surface J of the corresponding noble metal thin slice 32 in second overlapping region.Thereby Non-overlapping Domain is formed by the 33p ' of view field of the surface portion 33p of the second end face 33y, thus motive force by thrust piece 50 be applied to the part of the corresponding middleware 33 of Non-overlapping Domain of forming the 33p ' of view field on.
In this embodiment, thrust piece 50 is electrodes that are used for electric resistance welding, and is being formed with negative area 50a with noble metal thin slice 32 corresponding positions, so as a pushing force be applied to the corresponding surface portion 33p of Non-overlapping Domain on.Another strutting piece 51 as electrode is arranged on the opposite side of electrode body 4m.By supporting electrode body 4m and middleware 33 with compressing and supplying with and pass the electric current that it flows, can form electric resistance welding part R.Simultaneously, as shown in Figure 14, middleware 33 can be arranged in a side place at electrode body 4m to have in the blind hole 4u of an open end.Like this, become and to prevent intermediate host 33 and electrode body 4m displacement effectively.
Form through hole 4v or blind hole 4u therein so that therein among all embodiment of intermediate member arranged 33, cooperating between middleware 33 and through hole 4v or blind hole 4u can be loose fit.Yet cooperation can be a tight fit.By doing like this, can realize making the higher advantage of flexibility in execution in step, even be not used for preventing that noble metal thin slice and middleware component 34 from from the electrode body 4m side of any device of electrode body 4m landing, also preventing that by tight fit noble metal thin slice and middleware component 34 are from electrode body 4m landing because upset does not downwards provide.And, as shown in Figure 15 A and 15B, need not be respectively electrode side mating surface and middleware side mating surface be provided on the external peripheral surface of the inner circumferential surface of through hole 4v and middleware 33, can be used as composition surface to the external peripheral surface of the inner circumferential surface of through hole 4v and middleware 33, and by using friction tight coordinate force as motive force they to be bonded together ordinatedly.In Figure 15 A and 15B, by with the similar LASER BEAM WELDING part Q of Fig. 5, middleware 33 and electrode body 4m are bonded together.In this example, through hole 4v can be replaced by the blind hole 4u shown in Figure 16 A and the 16B.
Simultaneously, under the situation of using the blind hole 4u shown in Figure 16 A and the 16B, can use loose fit to replace tight fit.That is, keep electrode body 4m therein, noble metal thin slice and middleware component 34 are fitted loosely among the blind hole 4u, realize that simultaneously the second end face 33y of middleware 33 contacts with the bottom 4b of blind hole 4u so that allow the open end of blind hole 4u to remain under the condition of upside.By this method, motive force is not applied on the Non-overlapping Domain that forms in the second end face 33y.Yet, as shown in Figure 16 B, can form a similar LASER BEAM WELDING part Q with Figure 15 B down by the state shown in middleware 33 is remained on.That is, need not and be applied to motive force on middleware 33 and the noble metal thin slice 32 on the direction of engagement O, just can weld together electrode body 4m and middleware 33 and prevent its relative motion simultaneously by means of another part.
Example
In order to confirm the effect of the method according to this invention, carry out following test.Ir-40Rh alloy (promptly comprising the alloy of Ir as the Rh of main component and 40% weight) is prepared as the material that is used for being formed on the noble metal thin slice 32 on ground electrode 4 sides.The workpiece of this alloy or blank are forged 1500 ℃ of following heat and are made, and forge in 1300 ℃ of following hot roll extrusion or mould then, and descend further hot-drawns to provide the alloy silk of 1.4mm diameter at 1200 ℃.Cut off wire, and form the thin slice of the disc format of 1.4mm diameter and 0.6mm thickness thus.And middleware 33 is made by Ir-40Ni alloy (promptly comprising the alloy of Ir as the Ni of main component and 40% weight), and forms the disk of 2.2mm diameter and 0.6mm thickness.By LASER BEAM WELDING both are bonded together, and form noble metal thin slice and the middleware component of representing among Figure 13 A 34 thus.Noble metal thin slice and middleware component 34 are placed on the side surface (width with 2.8mm) of the electrode body of being made by Inconel 600 (trade (brand) name).Then,, promptly, carry out electric resistance welding, form the ground electrode of this example thus under the electric current supply of 12A and the power of a 380N only is applied on the surface portion of the middleware 33 that does not provide thin slice 32 by means of the method for representing among Figure 13 B.Simultaneously, for relatively, in an equal force pushing noble metal thin slice 32, produce a ground electrode by electric resistance welding.Then, by using ground electrode and central electrode, produce the sample (yet spark gap is 0.4mm) of the spark plug that is illustrated in the type among Fig. 1.
Separation resistivity for noble metal thin slice 32 is tested spark plug as follows.Promptly, make the spark-discharge gap side of each spark plug stand to circulate heating and cooling (promptly, by using a burner to be heated to 1000 ℃ of two minutes and air coolings one minute), and the number of times of the heating and cooling circulation that spark plug stands before taking place according to the separation at the noble metal thin slice estimates to separate resistivity.Pass through result of the test, confirm to use therein in the spark plug of ground electrode of comparative example, the separation of sheet metal 32 takes place after 1200 circulations, and it is different therewith, therein in the spark plug of the demonstration ground electrode of producing by method of the present invention, even after 3000 circulations, do not cause the separation of sheet metal 32 yet.Thereby confirm to have favorable durability by the spark plug of method manufacturing of the present invention.
The full content of Japanese patent application P2002-051291 (being filed on February 27th, 2002) is included in here by reference.
Although with reference to of the present invention some the present invention has been described more than the embodiment, the invention is not restricted to the foregoing description.Can expect the modifications and changes of the foregoing description for those skilled in the art in view of above instruction.Scope of the present invention limits with reference to following claims.
Claims (18)
1. method of making spark plug, this spark plug comprises: a ground electrode has an electrode body; With a noble metal thin slice, join on the electrode body by between it, inserting a middleware, the noble metal thin slice is arranged to limit a spark-discharge gap facing to a central electrode and between it, and the method comprising the steps of:
Before joining to the noble metal thin slice on the electrode body, middleware and noble metal thin slice are bonded together, and form a noble metal thin slice and middleware component thus;
Noble metal thin slice and middleware component are placed on the electrode body in such a way, thereby allow middleware contact electrode main body; And
The middleware of electrode body and noble metal thin slice and middleware component is welded together, limit the relative motion of the middleware of electrode body and noble metal thin slice and middleware component simultaneously, and need not be applied to thrust on the composition surface between middleware and the noble metal thin slice by using another part.
2. method according to claim 1, wherein welding step comprises the middleware LASER BEAM WELDING of electrode body and noble metal thin slice and middleware component is in the same place.
3. method according to claim 1, wherein welding step comprises the middleware of resistance welded electrode body and noble metal thin slice and middleware component.
4. method according to claim 1, wherein engagement step comprises middleware and noble metal thin-disc laser bundle is welded together.
5. method according to claim 1, wherein
The placement step comprises:
Consider that the projected area of the composition surface of middleware and electrode body becomes a minimum projection plane thereon;
On projection plane in the rectangular projection of middleware and electrode body, is a zone definitions that overlaps each other in the view field of its place's middleware and electrode body one first overlapping region, is a zone definitions that overlaps each other in the view field of its place's middleware and noble metal thin slice one second overlapping region, and the part of first overlapping region that does not belong to second overlapping region is defined as a Non-overlapping Domain; And wherein
Welding step comprises:
Being used for promoting the be fitted to each other thrust that contacts of middleware and electrode body to one is applied on the part with the corresponding middleware of Non-overlapping Domain of first overlapping region.
6. method according to claim 1 is wherein placed step and is comprised: in electrode body, forms and to have one of a through hole that has an open end at its place, side facing to central electrode or blind hole; And noble metal thin slice and middleware component are inserted in one of through hole or blind hole in such a way, thereby allow the noble metal thin slice outstanding from the open end of one of through hole or blind hole.
7. method according to claim 1, wherein placing step comprises: in electrode body, form one have facing to place, the side of central electrode one first open end with the through hole that has one second open end facing to relative place, side, the side of central electrode; And noble metal thin slice and middleware component are inserted in the through hole through first open end, thereby allow the noble metal thin slice outstanding from second open end, the middleware side mating surface of inner surface neutralization that allows an electrode side mating surface to be formed on through hole simultaneously is formed in the middleware so that be engaged with each other, and prevents thus that middleware is inserted into middleware on the direction of insertion in the through hole therein and throw off.
8. method according to claim 7, wherein welding step comprises by pushing middleware by means of a thrust piece on direction of insertion and produces a motive force.
9. method according to claim 8, wherein welding step comprises: thrust piece is used as welding electrode; Part with resistance welded and corresponding electrode body of Non-overlapping Domain and middleware.
10. method according to claim 7, wherein placing step comprises: be placed on noble metal thin slice and middleware component on the electrode body in such a way, thereby allow middleware to be positioned at the electrode body top, and allow middleware to be pushed against on the electrode body, and thus motive force is applied on the part with corresponding electrode body of Non-overlapping Domain and middleware by gravity.
11. method according to claim 6 is wherein placed step and is comprised: the middleware of noble metal thin slice and middleware component is force-fitted in one of through hole and blind hole.
12. method according to claim 10, wherein welding step comprises the middleware and the electrode body of LASER BEAM WELDING noble metal thin slice and middleware component.
13. method according to claim 1 is wherein placed step and is comprised: in electrode body, form a blind hole; End face that it is engaged the middleware of noble metal thin slice is defined as one first end face and an end face of the middleware relative with first end face is defined as one second end face; And noble metal thin slice and middleware component are arranged in the blind hole in such a way, thereby allow second end face to contact the lower surface of blind hole.
14. method according to claim 5 is wherein placed step and is comprised: end face that it is engaged the middleware of noble metal thin slice is defined as one first end face and an end face of the middleware relative with first end face is defined as one second end face; Be placed on noble metal thin slice and middleware component on the electrode body in such a way, thereby allow the second end face contact electrode main body of middleware, and wherein welding step comprises: the part with the corresponding middleware of Non-overlapping Domain is pushed against on the electrode body by means of a thrust piece.
15. method according to claim 14 is wherein placed step and is comprised: the middleware of noble metal thin slice and middleware component is placed in the blind hole that is formed in the electrode body, so that have an open end at a side place of electrode body.
16. method according to claim 1, further comprise: before engagement step, end face that it is engaged the middleware of noble metal thin slice is defined as one first end face and an end face of the middleware relative with first end face is defined as one second end face; And form a blind hole that has an open end in second end in middleware, wherein welding step comprises the LASER BEAM WELDING that is applied to the blind hole bottom, so that middleware and noble metal thin slice are welded together.
17. method according to claim 1, wherein the noble metal thin slice is made by a kind of Ir alloy.
18. method according to claim 1, wherein middleware is made by the metal with the linear expansion coefficient between the metal that forms noble metal thin slice and electrode body.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP051291/2002 | 2002-02-27 | ||
| JP2002051291A JP4028256B2 (en) | 2002-02-27 | 2002-02-27 | Manufacturing method of spark plug |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN1463061A true CN1463061A (en) | 2003-12-24 |
| CN100352117C CN100352117C (en) | 2007-11-28 |
Family
ID=27678509
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CNB031378730A Expired - Fee Related CN100352117C (en) | 2002-02-27 | 2003-02-27 | Method of mfg. spark plug |
Country Status (4)
| Country | Link |
|---|---|
| US (1) | US6923699B2 (en) |
| EP (1) | EP1341282B1 (en) |
| JP (1) | JP4028256B2 (en) |
| CN (1) | CN100352117C (en) |
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| CN101861686B (en) * | 2007-11-15 | 2012-12-26 | 日本特殊陶业株式会社 | Spark plug |
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| CN104638520A (en) * | 2013-11-12 | 2015-05-20 | 日本特殊陶业株式会社 | Spark plug and method of manufacturing spark plug |
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-
2003
- 2003-02-26 US US10/372,830 patent/US6923699B2/en not_active Expired - Lifetime
- 2003-02-27 CN CNB031378730A patent/CN100352117C/en not_active Expired - Fee Related
- 2003-02-27 EP EP03004316A patent/EP1341282B1/en not_active Expired - Lifetime
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN101010840B (en) * | 2004-02-03 | 2011-03-02 | 联邦摩古点燃(英国)有限公司 | Spark plug configuration having a metal noble tip |
| CN101529678B (en) * | 2005-11-18 | 2012-10-10 | 费德罗—莫格尔公司 | Method of forming a spark plug with multi-layer firing tip |
| US8052495B2 (en) | 2007-03-28 | 2011-11-08 | Ngk Spark Plug Co., Ltd. | Method for producing spark plug by projection welding and spark plug thereof |
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| CN101276998B (en) * | 2007-03-28 | 2012-05-02 | 日本特殊陶业株式会社 | Method for producing spark plug and spark plug |
| CN101861686B (en) * | 2007-11-15 | 2012-12-26 | 日本特殊陶业株式会社 | Spark plug |
| CN103094842A (en) * | 2013-01-18 | 2013-05-08 | 株洲湘火炬火花塞有限责任公司 | Manufacture method for spark plug compound electrode tip and compound electrode tip band |
| CN104638520A (en) * | 2013-11-12 | 2015-05-20 | 日本特殊陶业株式会社 | Spark plug and method of manufacturing spark plug |
Also Published As
| Publication number | Publication date |
|---|---|
| EP1341282A2 (en) | 2003-09-03 |
| US6923699B2 (en) | 2005-08-02 |
| JP2003257581A (en) | 2003-09-12 |
| CN100352117C (en) | 2007-11-28 |
| EP1341282B1 (en) | 2011-07-27 |
| US20030181121A1 (en) | 2003-09-25 |
| JP4028256B2 (en) | 2007-12-26 |
| EP1341282A3 (en) | 2008-03-26 |
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